一.

Overview
The ECS-10D fuel gas dual fuel engine (power generation) control system can precisely
control the ratio of engine fuel and gas, and can ensure that the engine runs at a stable speed
under different working conditions.The steady-state and dynamic indicators of the system are set
with conventional general parameters when leaving the factory, which can generally meet the
requirements for most users or models. If instability occurs, the original speed control system can
be adjusted.
The working principle of the ECS-10D system is to calculate the total flow of the mixture
entering the engine based on the engine speed density method. The gas flow is calibrated by the
theoretical calculation of the gas flow in the pipeline and the measured flow coefficient to obtain
the actual instantaneous gas flow.Its flow accuracy error is less than 3%, which can control gas
flow according to speed, pressure, differential pressure and temperature under any engine load
and operating conditions.The ECS-10D controller cooperates with the LK series gas flow control
unit to complete the precise control of the gas flow of different concentrations, ensuring that the
engine runs at the set fuel substitution rate, so that the engine can exert the best performance.
This is a dual-fuel The ideal control solution for the engine.The biggest advantage of the system is
that it can adapt to a wide range of changes in gas heating value, and can achieve flexible control
of engine stability, transient performance and emission performance.
The controller is suitable for a wide range of gas sources, suitable for various components of
gas, and also has a wide range of intake pressure requirements, the system can adapt to various
occasions of different models.

二. electrical parameters
Power supply: 20～32V DC, 10A max
Rated/idle speed regulation range: 0～9KHz
Synchronous control range: 0～5V
Output overcurrent protection: >4A 5s
Input device: 1-way speed sensor input
1 way oxygen sensor input
1-way manifold pressure temperature sensor input
1-way parallel port
1-way high and low speed switch
Output device: 1-way actuator output
1-way LKxxx gas flow control unit connection output
1-way communication output
Working temperature: -20℃~+70℃
Protection class: IP56

三. System General Arrangement

 Air filter LK Gas flow control

Mixer Venture

Oxygen sensor
Turbo

Engine control unit(ECS)

Absolute pressure sensor

Engine Speed sensor

四. System installation

4.1 Installation of speed sensor

The speed sensor uses a magnetoelectric sensor. The function of the speed sensor is to
collect the engine speed signal and input it to the ECU to calculate the engine speed and control
the electronic throttle opening to control the intake air volume, thereby controlling the engine
speed.This sensor communicates with the ECU through a 2-wire connector. Installation position:
installed on the flywheel housing, as shown in the figure
 Engine shell F
Speed sensor
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Nut e
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4.2 Manifold Pressure Temperature Sensor Installation

The MAP sensor is the core sensor of the system and is used to measure the absolute
pressure of the intake port after the engine speed control valve. Signal type is 0-5Vdc.
The MAP sensor should be installed in a position to avoid high temperature, oil, water, and
at the same time higher than the measurement sampling point.The location of the measurement
sampling point should be located behind the speed control valve, in the upper part of the air inlet
to prevent oil, water or foreign matter from entering the sensor.The measurement sampling point
should be able to reflect the average pressure of the intake port, do not rely on the intake valve,
speed control valve or the end of the intake port to avoid measurement errors caused by strong
turbulence.MAP sensor cables should be kept away from high voltage lines such as ignition coils
and high voltage wires.

Intercooler room

Bolts&nuts

MAP sensor
4.3 Oxygen sensor installation
Installation location: The oxygen sensor is installed on the exhaust main pipe connected to the
exhaust main pipe, about 30cm away from the main pipe outlet.
Installation Specifications:
--The head of the oxygen sensor is as close as possible to the place on the engine where the
exhaust gas composition is most representative (ie the mixture of exhaust gas from each cylinder
measured by the sensor).
--Tilt 45° from vertical with electrical connector up
--When assembling, apply special grease to the threads. (Grease is already on the product)
--The sensor must be tightened to prevent leakage
--When tightening, do not force the fitting too hard, otherwise it will cause irreparable damage
to the oxygen sensor.
Installation size:

4.4 LKxxx Gas Flow Control Unit Installation

The installation requirements of the LKxxx unit are as close as possible to the engine. Pay
attention to the flow direction of the gas during installation. The direction arrow of the air flow is
printed on the shell panel of the control unit. Install in the direction indicated by the arrow. The
flange connection is reliably sealed, and the control unit itself has been tested for air tightness.
Control unit parameters:
- Supply voltage 24V
- Maximum current 10A
- Pipe inner diameter Ф52, Ф75, Ф105, Ф160
- Motor rotation angle 75°
- Inlet pressure range 2～25KPa

4.5 ECS-10D installation

The ECU is installed on the engine or in the control room, and the installation dimensions are
as shown in the figure

五. Instructions for use

5.1 Software installation and device connection

Double-click the installer Choose the installation path:

Click to install now

Wait for the software installation to complete

5.2 Engine parameter setting

Double-click the desktop program icon run the program.Select the correct COM port
and click the Open button.

Select "Parameter Settings" to set engine parameters and gas parameters.

5.3 Actuator Position Calibration
Turn the actuator connecting rod to the minimum position, observe the actuator position on
the "Engine Status" interface, record and input it to the "Motor Minimum Position"; then turn
the actuator connecting rod to the maximum position, observe the execution on the "Engine
Status" interface the position of the motor, record and enter it into "Motor Max Position".
六. Possible fault symptoms, causes and troubleshooting methods
Improper operation of the engine is usually the main cause of various engine failures. When
a fault occurs, you should first confirm whether the engine itself is in a normal state. Therefore,
the control system should be disconnected from the engine first, and then the cause of the
failure should be determined.
If the controller has abnormal phenomena during installation, debugging and use, please
refer to Table 1 to deal with it. If the fault is still not eliminated after checking and handling
according to the table below, and it is confirmed that there is no problem with the engine system,
please contact the manufacturer. Users who do not have maintenance conditions, please do not
blindly dismantle and repair, so as not to expand the failure.

issue Possible Causes Solution

After checking the pressure reducing valve, the KP
The gas pipeline is gauge pressure should be kept greater than 2KP. If
blocked or the flow is the pressure drops to 0 at startup, the intake
not enough pressure should be increased or the diameter of the
intake pipe should be increased.
Push the actuator connecting rod by hand to confirm
Engine won't Actuator stuck that the actuator rotates flexibly. If stuck, it
start should be replaced.
Unplug the socket from the controller. Measure +24V
Controller has no power
on the +24V power and ground pins.
The Stoping switch is Check the position of the toping switch to confirm
not disconnected that the toping switch is reliable.
MPU installation Remove the MPU and reinstall as instructed. Manually
clearance is too large crank to check for interference.
 Disconnect governor connector. When cranking, check
MPU signal connection
that the voltage between MPU+ and MPU- should be at
open
least 1V.
Observe the air-fuel ratio, too rich or too lean to
Air fuel ratio error start the engine; adjust the gas parameters or the
VE/λ table.
Incorrect overspeed Check the overspeed protection point configuration
setpoint configuration settings.
Incorrect overspeed Check the overspeed protection point configuration
setpoint configuration settings.
Improper transient gain
Increase gain to reduce overshoot.
Engine start setting
overspeed Incorrect number of
The parameters are reset by software.
flywheel teeth
The speed control
Check the actuator.
actuator is stuck
Inappropriate speed PID Using the service tool, adjust the position dynamics
adjustment parameters. Default in most cases.
Observe the air-fuel ratio, too rich or too lean will
Inappropriate air-fuel
lead to unstable speed; adjust the gas parameters or
ratio
the VE/λ table.
Inappropriate ignition
engine unstable Adjust the ignition advance angle.
advance angle
Intermittent or Check the reliability of the speed signal shielding.
incorrect tach signal Check whether the speed input line is unblocked.
Carbon deposits on
spark plugs, rust on Replace with new spark plugs and high-voltage wires.
high-voltage wires